4-cyl. common rail (2.0 l, 4V, turbocharger, EA 288 EVO)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with start/stop system
  2
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on SCR system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  5
• 2.1 Engine number/engine data
  5
• 3 Repair instructions
  7
• 3.1 Rules for cleanliness
  7
• 3.2 Foreign objects in engine
  7
• 3.3 Contact corrosion
  7
• 3.4 Routing and attachment of lines
  8
• 3.5 Fitting radiator and condensers
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  22
• 1.3 Securing engine on engine and gearbox support
  27
• 1.4 Installing engine
  29
• 2 Assembly mountings
  34
• 2.1 Assembly overview – assembly mountings
  34
• 2.2 Removing and installing engine mounting
  36
• 2.3 Removing and installing gearbox mounting
  37
• 2.4 Removing and installing pendulum support
  39
• 2.5 Supporting engine in installation position
  40
• 2.6 Adjusting assembly mountings
  45
• 2.7 Checking adjustment of assembly mountings
  47
• 3 Engine cover panel
  49
• 3.1 Removing and installing engine cover
  49
• Crankshaft group
  50
• 1 Cylinder block (pulley end)
  50
• 1.1 Assembly overview - cylinder block (pulley end)
  50
• 1.2 Assembly overview - sealing flange, belt pulley end
  53
• 1.3 Removing and installing poly-V belt
  54
• 1.4 Removing and installing tensioner for poly V-belt
  56
• 1.5 Removing and installing vibration damper
  56
• 1.6 Removing and installing bracket for ancillaries
  57
• 1.7 Removing and installing engine support
  59
• 1.8 Removing and installing sealing flange on pulley end
  61
• 1.9 Renewing caps in cylinder block (pulley end)
  63
• 2 Cylinder block, gearbox end
  65
• 2.1 Assembly overview - cylinder block, gearbox end
  65
• 2.2 Removing and installing flywheel
  68
• 2.3 Removing and installing sealing flange on gearbox side
  70
• 2.4 Renewing caps in cylinder block (gearbox end)
  94
• 3 Crankshaft
  96
• 3.1 Measuring axial clearance of crankshaft
  96
• 3.2 Renewing needle bearing in crankshaft
  97
• 4 Pistons and conrods
  100
• 4.1 Assembly overview - pistons and conrods
  100
• 4.2 Removing and installing pistons
  105
• 4.3 Measuring piston projection at TDC
  107
• 4.4 Checking pistons and cylinder bores
  109
• 4.5 Checking radial clearance of conrods
  112
• Cylinder head, valve gear
  113
• 1 Cylinder head
  113
• 1.1 Assembly overview - cylinder head
  113
• 1.2 Assembly overview - cylinder head cover
  117
• 1.3 Removing and installing cylinder head
  119
• 1.4 Removing and installing cylinder head cover
  131
• 1.5 Removing and installing injector seals
  132
• 1.6 Removing and installing camshaft housing
  133
• 1.7 Checking compression
  140
• 2 Toothed belt drive
  144
• 2.1 Assembly overview - toothed belt cover
  144
• 2.2 Assembly overview - toothed belt
  145
• 2.3 Removing and installing toothed belt guard
  147
• 2.4 Removing and installing toothed belt
  151
• 2.5 Removing toothed belt from camshaft
  164
• 3 Valve gear
  174
• 3.1 Assembly overview - valve gear
  174
• 3.2 Measuring axial play of camshaft
  176
• 3.3 Removing and installing camshaft oil seal
  177
• 3.4 Checking hydraulic compensation elements
  179
• 3.5 Removing and installing valve stem oil seals
  180
• 4 Inlet and exhaust valves
  197
• 4.1 Checking valve guides
  197
• 4.2 Checking valves
  198
• 4.3 Valve dimensions
  198
• Lubrication
  200
• 1 Sump, oil pump
  200
• 1.1 Assembly overview - sump/oil pump
  200
• 1.2 Engine oil:
  204
• 1.3 Removing and installing lower part of sump
  204
• 1.4 Removing and installing upper part of sump
  209
• 1.5 Removing and installing oil pump
  212
• 1.6 Removing and installing oil level and oil temperature sender G266
  213
• 2 Engine oil cooler
  215
• 3 Oil filter, oil pressure switch
  216
• 3.1 Assembly overview - oil filter housing
  216
• 3.2 Exploded view - oil pressure switches
  218
• 3.3 Removing and installing oil pressure sender G10
  219
• 3.4 Checking oil pressure
  220
• 3.5 Removing and installing oil filter housing
  221
• 3.6 Removing and installing oil pressure regulating valve N428
  223
• 3.7 Removing and installing piston cooling jet control valve N522
  224
• 4 Oil circuit
  225
• 4.1 Removing and installing oil supply line
  225
• 4.2 Removing and installing oil return line for turbocharger
  226
• Cooling
  228
• 1 Cooling system/coolant
  228
• 1.1 Connection diagram - coolant hoses
  228
• 1.2 Checking cooling system for leaks
  230
• 1.3 Draining coolant
  233
• 1.4 Filling with coolant
  235
• 1.5 Checking filling quality of cooling system
  255
• 1.6 Flushing cooling system
  257
• 2 Coolant pump, regulation of cooling system
  279
• 2.1 Assembly overview - coolant pump, thermostat
  279
• 2.2 Assembly overview - electric coolant pump
  282
• 2.3 Assembly overview - coolant temperature sender
  284
• 2.4 Removing and installing electric coolant pump
  286
• 2.5 Removing and installing coolant pump
  294
• 2.6 Removing and installing coolant distribution module
  296
• 2.7 Removing and installing coolant regulating valve N515
  299
• 2.8 Removing and installing coolant temperature sender G62
  300
• 2.9 Removing and installing engine outlet coolant temperature sender G82
  302
• 2.10 Removing and installing coolant temperature sender for charge air cooler G1130
  304
• 3 Coolant pipes
  307
• 3.1 Assembly overview - coolant pipes
  307
• 3.2 Removing and installing coolant pipes
  308
• 4 Radiator, radiator fan
  316
• 4.1 Assembly overview - radiator/radiator fan
  316
• 4.2 Assembly overview – radiator cowl and radiator fan
  319
• 4.3 Removing and installing radiator
  320
• 4.4 Removing and installing water radiator for charge air cooling circuit
  322
• 4.5 Removing and installing radiator cowl
  328
• 4.6 Removing and installing radiator fan
  329
• Turbocharging/supercharging
  331
• 1 Turbocharger
  331
• 1.1 Assembly overview - turbocharger
  331
• 1.2 Removing and installing turbocharger
  334
• 1.3 Removing and installing connection for turbocharger
  339
• 2 Charge air system
  341
• 2.1 Assembly overview - charge air system
  341
• 2.2 Removing and installing charge pressure sender GX26
  341
• 2.3 Checking charge air system for leaks
  341
• 2.4 Removing and installing air intake pipe
  344
• 2.5 Checking charge air cooler for leaks
  346
• 2.6 Assembly overview - charge-air hose connections
  350
• Mixture preparation - injection
  352
• 1 Injection system
  352
• 1.1 Schematic overview - fuel system
  352
• 1.2 Overview of fitting locations - injection system
  354
• 1.3 Filling/bleeding fuel system
  366
• 1.4 Checking fuel system for leaks
  366
• 2 Injectors/high-pressure accumulator (rail)
  368
• 2.1 Assembly overview - injectors
  368
• 2.2 Assembly overview - fuel rail
  370
• 2.3 Adapting correction values for injectors
  371
• 2.4 Testing injectors
  372
• 2.5 Checking return flow rate of injectors with engine running
  373
• 2.6 Checking return flow rate of injectors at starter speed
  376
• 2.7 Checking open injectors
  378
• 2.8 Removing and installing injectors
  379
• 2.9 Removing and installing high-pressure lines
  384
• 2.10 Removing and installing fuel rail
  389
• 3 Air filter
  394
• 3.1 Assembly overview - air filter housing
  394
• 3.2 Removing and installing air filter housing
  396
• 3.3 Removing and installing air guide on lock carrier
  398
• 4 Intake manifold
  400
• 4.1 Assembly overview – intake manifold
  400
• 4.2 Removing and installing intake manifold
  405
• 4.3 Removing and installing throttle valve module GX3
  412
• 5 Senders and sensors
  415
• 5.1 Removing and installing fuel pressure regulating valve N276
  415
• 5.2 Checking fuel pressure regulating valve N276
  417
• 5.3 Removing and installing fuel pressure sender G247
  419
• 5.4 Removing and installing air mass measurement module GX35
  421
• 5.5 Removing and installing pressure differential sender G505
  423
• 5.6 Removing and installing NOx sender 2 G687
  424
• 5.7 Removing and installing NOx sender 3 G932
  426
• 5.10 Removing and installing NOx sender G295
  429
• 5.11 Removing and installing particle sensor G784
  431
• 6 Engine control unit
  435
• 6.1 Removing and installing engine control unit J623
  435
• 6.2 Removing and installing engine control unit J623 (with protective housing)
  436
• 7 High-pressure pump
  443
• 7.1 Assembly overview - high-pressure pump
  443
• 7.2 Removing and installing high-pressure pump
  443
• 8 Lambda probe
  448
• 8.1 Assembly overview - Lambda probe
  448
• 8.2 Removing and installing Lambda probe
  449
• Exhaust system
  451
• 1 Exhaust pipes and silencers
  451
• 1.1 Assembly overview – silencers
  451
• 1.2 Assembly overview - front exhaust pipe
  452
• 1.3 Separating exhaust pipes from silencers
  456
• 1.4 Removing and installing silencer
  457
• 1.5 Aligning exhaust system free of stress
  459
• 1.6 Checking exhaust system for leaks
  459
• 1.7 Installation position of clamp
  459
• 1.8 Align end exhaust pipes
  461
• 2 Emission control
  462
• 2.1 Assembly overview – emission control
  462
• 2.2 Removing and installing emission control module
  464
• 2.3 Removing and installing exhaust flap control unit J883
  472
• 2.4 Removing and installing ammonia traps
  474
• 3 SCR system (selective catalytic reduction)
  477
• 3.1 Assembly overview – reducing agent tank
  477
• 3.2 Assembly overview - reducing agent supply line
  479
• 3.3 Assembly overview - delivery unit for reducing agent metering system GX19
  482
• 3.4 Removing and installing reducing agent tank
  483
• 3.5 Removing and installing front section of reducing agent supply line
  485
• 3.6 Removing and installing delivery unit for reducing agent metering system GX19
  489
• 3.7 Removing and installing injector for reduction agent N474
  491
• 3.8 Removing and installing injector 2 for reducing agent N758
  493
• 3.9 Removing and installing control unit for reducing-agent heater J891
  495
• 3.10 Assembly overview - injector for reducing agent N474
  498
• 3.11 Assembly overview – injector 2 for reducing agent N758
  499
• 3.12 Draining reducing agent tank
  500
• 3.13 Removing and installing middle section of reducing agent supply line
  504
• 3.14 Removing and installing rear section of reducing agent supply line
  505
• 3.15 Removing and installing filler pipe for reducing agent tank
  508
• 3.16 Disconnecting reducing agent supply line
  509
• 3.17 SCR - resetting learnt values
  515
• 4 Exhaust gas temperature regulation
  516
• 4.1 Assembly overview – exhaust gas temperature regulation
  516
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  517
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  519
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  521
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  523
• 5 Exhaust gas recirculation
  527
• 5.1 Assembly overview – exhaust gas recirculation
  527
• 5.2 Removing and installing exhaust gas recirculation cooler
  530
• 5.3 Removing and installing exhaust gas recirculation valve 1 GX5
  533
• 5.4 Removing and installing exhaust gas recirculation valve 2 GX6
  534
• 5.5 Removing and installing exhaust gas recirculation temperature sensor G98
  536
• 5.6 Checking exhaust gas recirculation cooler for leaks
  537
• Glow plug system
  542
• 1 Glow plug system
  542
• 1.1 Assembly overview – glow plug system
  542
• 1.2 Removing and installing glow plug
  544
• 1.3 Removing and installing automatic glow period control unit J179
  548
• 1.4 Removing and installing Hall sender G40
  549
• 1.5 Removing and installing engine speed sender G28
  550